Transversal generator set and modular design for refurbishment of locomotives

ABSTRACT

A generator set has a transversal configuration on the locomotive. The generator set and its configuration on the platform offer good performance with respect to the space it occupies along the length of the locomotive platform deck, and offer better access for maintenance purposes. A walkway interface structure supports a modular design for locomotives using standardized major sub-assemblies that can be easily interfaced from one locomotive and under-frame to another.

CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefit, under 35 U.S.C. §119(e), ofU.S. Provisional Application 60/929,286 entitled “Transversal GeneratorSet and Modular Design for Refurbishment of Locomotives” to Burns et alfiled Jun. 20, 2007, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to the refurbishment of trainlocomotives, or the like. More particularly, it relates to a transversalmodular generator set to be installed on a locomotive during itsrefurbishment. The present invention also relates to a modular designconcept which facilitates the refurbishment of locomotives through theuse of a walkway interface system and standardized locomotive majorsub-assemblies.

BACKGROUND OF THE INVENTION

Refurbishment of locomotive generator sets is carried out often thesedays as a cost-effective way for replacing older locomotives that mayotherwise have other highly functional subsystems (such as tractionmotors, brakes, trucks and the undercarriage of the locomotive) that canstill used over a period of several years with minor maintenance.

In older locomotives, sub-systems like the generator set (genset), aircompressor, dynamic brake, etc. are directly applied to the locomotiveplatform. Consequently, for every refurbishment project and everyplatform generation, the interface between the sub-systems and thelocomotive platform needs to be re-engineered. Normally, the gensetpackage is oriented along the longitudinal axis of the locomotive.

FIG. 1 illustrates a longitudinal configuration of gensets on alocomotive 10. The gensets 12 are placed in a longitudinal arrangementon the locomotive. The locomotive must also sometimes accommodate on theplatform deck plates 18 a dynamic brake thereon, as well as aircompressor and rear sand box systems 16. The locomotive illustrated inFIG. 2 is a GP-9 platform with three gensets 12 placed in a longitudinalconfiguration, with no dynamic brake.

In order to address spacing issues of gensets, Stauffer et al. haveproposed in U.S. Pat. No. 6,230,667 and U.S. Pat. No. 5,908,011 areduced-length engine generator assembly. The arrangement of componentsin these gensets permits an assembly with a shorter overall length,while avoiding any significant increase in height, thus facilitatinginstallation aboard vehicles.

Furthermore, refurbishment of gensets on locomotives of differentlengths is complicated due to the fact that, when longitudinal orside-by-side configurations are used, the actual design and layout ofthe gensets needs to be adapted to each and every new platform length.As illustrated in the following table, the platform lengths oflocomotives vary significantly from one locomotive model to another:

Original Locomotive Model Platform Length GP-38 55′ SW-1500 40′3″ GP-952′ B23-7, B30-7A 58′4″ (V1, V2), 57′4″ (V3) SD-40 64′8″

There is a lack of standardization in the major sub-assemblies of thelocomotive which often prevents the use or transfer of one sub-assemblyfrom one particular locomotive and under-frame to another locomotive andunder-frame. There is also a lack of standardization in common interfaceassemblies that could also be used for the transfer of one sub-assemblyfrom one particular locomotive and under-frame to another locomotive andunder-frame.

Thus, there is still presently a need for a locomotive generator set, aswell as a configuration of the generator set on the locomotive, whichcan offer good performance with respect to the space it occupies alongthe length of the locomotive platform deck, and offer better access formaintenance purposes.

There is also a need for a modular design for locomotives usingstandardized major sub-assemblies that can be easily interfaced from onelocomotive and under-frame to another.

SUMMARY OF THE INVENTION

Another object of the present invention is to propose a layout for thegenerator set on the locomotive platform deck that satisfies another oneof the above-mentioned needs.

Yet another object of the present invention is to provide a walkwayinterface system and standardized locomotive major sub-assemblies thatsatisfy another one of the above-mentioned needs.

According to the present invention, there is provided a locomotivecomprising:

-   -   a platform deck; and    -   a plurality of generator sets on the platform deck, each        generator set occupying a space associated with a generally        oblong footprint on the platform deck, the footprint defining a        longitudinal axis along a longest length of the footprint,        wherein each generator set is positioned on the platform deck        such that the longitudinal axis of the corresponding footprint        is generally perpendicular to a direction of travel of the        locomotive.        Preferably, the generator set comprises:    -   an engine generally oblong along an engine major axis;    -   a fuel line supplying fuel to the engine through a fuel filter;    -   an oil line supplying oil to the engine through an oil filter;    -   an electrical subsystem connected to the engine comprising:        -   an alternator driven by the engine, the alternator being            generally oblong along an alternator major axis, the            alternator major axis being generally parallel to the engine            major axis; and        -   a junction box for power management of the electrical            subsystem and positioned on the first side of the            alternator;    -   an air passage supplying intake air to the engine through an air        filter, the air filter being generally oblong along an air        filter major axis, the air filter being positioned above the        alternator and the air filter major axis being generally        perpendicular to the alternator major axis;    -   an exhaust pipe for removal of exhaust gases from the engine        through a muffler, the muffler being generally oblong along a        muffler major axis, the muffler being positioned above the        engine, the muffler major axis being generally parallel to the        engine major axis;    -   a radiator system for cooling of the generator set and connected        to the engine, the radiator system being positioned above the        engine; and    -   an operating panel for control of the generator set.

According to the present invention, there is also provided a walkwayinterface structure for supporting a locomotive sub-assembly on alocomotive platform having a platform width, the walkway interfacestructure comprising:

-   -   a base structure adapted to be removably placed on the        locomotive platform, the base structure supporting the        locomotive sub-assembly and having a base width substantially        corresponding to the platform width; and    -   at least one interface means traversing the base structure for        operatively connecting the locomotive sub-assembly to another        locomotive sub-system.

Preferably, the interface means comprises an element selected from thegroup consisting of traction motor cables, generator set power cables,dynamic brake power cables, power wires, control harnesses, fuel lines,drains, piping lines or ducting.

The transversal genset according to the present invention offers abetter HP/linear feet ratio compared to most actual locomotives withtheir gensets aligned along the length of the locomotive. The presentgenset also offers better access for maintenance purposes with fullaccess to all sides of the genset. The genset according to the presentinvention also simplifies hood designs, as much less doors are requiredfor access to the genset. Furthermore, the present genset is designed tocomply with an overall modularity and parametrization concept forlocomotives.

The concept of a modular design consists of having standardized majorsub-assemblies that can be easily interface from one locomotive andunder-frame to another. The main benefits of this concept include:

-   -   Reduced engineering and drafting time for new locomotive orders    -   Simplified Manufacturing    -   Cost savings    -   Quicker Time to Market    -   Improved Reliability    -   Reduction in Design Documentation    -   Design Parameterization

The walkway interface structure according to the present inventionprovides a structure to be added over the full width of the platform andprovides a number of pre-run cables and pipes to standardized locationson the locomotive. These types of interface structures, in combinationwith standardized sub-assemblies, including the gensets in accordancewith the present invention, can be grouped together in differentconfigurations to meet customer needs.

A non-restrictive description of preferred embodiments of the inventionwill now be given with reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a prior art locomotive with gensetspositioned in a longitudinal configuration along the length of theplatform;

FIG. 2 is an opposite perspective view of the locomotive shown in FIG.1;

FIG. 3 is a perspective view of a genset according to a preferredembodiment of the present invention;

FIG. 4 shows a layout of the footprints of gensets in a transverseconfiguration with respect to actual and side-by-side configurations;

FIG. 5 is an exploded perspective view of a locomotive with modulartransversal gensets in accordance with another preferred embodiment ofthe present invention;

FIG. 6 is an opposite exploded perspective view of the locomotive shownin FIG. 5;

FIG. 7 is a perspective view of a locomotive with modular transversalgensets in accordance with a preferred embodiment of the presentinvention;

FIG. 8 is an opposite perspective view of the locomotive shown in FIG.7;

FIG. 9 is a side view of the locomotive shown in FIG. 7;

FIG. 10 is an opposite side view of the locomotive shown in FIG. 9;

FIG. 11 is a perspective view of a locomotive with walkway interfacestructures and gensets in a transverse configuration in accordance withanother preferred embodiment of the present invention;

FIGS. 12A-12C are perspective views of locomotives with differentconfigurations of walkway interface structures and gensets in atransverse configuration in accordance with other preferred embodimentsof the present invention;

FIG. 13 is a perspective view of a locomotive with walkway interfacestructures and gensets in a longitudinal configuration in accordancewith yet another preferred embodiment of the present invention;

FIGS. 14A-14C are perspective views of locomotives with differentconfigurations of walkway interface structures and gensets in alongitudinal configuration in accordance with other preferredembodiments of the present invention.

FIG. 15 is a perspective view of a locomotive with walkway interfacestructures and gensets in accordance with another preferred embodimentof the present invention;

FIG. 16 is an exploded perspective view of the locomotive shown in FIG.15;

FIG. 17 is a perspective view of a walkway interface structure accordingto a preferred embodiment of the present invention;

FIG. 18 is a perspective sectional view of the walkway interfacestructure shown in FIG. 17; and

FIG. 19 is a side view the walkway interface structure shown in FIG. 17.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIG. 4 for a schematic view and FIGS. 5-6 for explodedperspective views, the present invention provides a locomotive 30comprising a platform deck 32 and a plurality of generator sets 34 onthe platform deck 32, each generator set 34 occupying a space associatedwith a generally oblong footprint 36 on the platform deck 32, thefootprint 36 defining a longitudinal axis along a longest length of thefootprint 36. Each generator set 34 is positioned on the platform deck32 such that the longitudinal axis of the corresponding footprint 36 isgenerally perpendicular to a direction of travel of the locomotive 30.

As explained previously, this layout of the generator sets on theplatform has a number of advantages. A comparison of this transversalconfiguration of gensets with respect to prior art configurations isillustrated schematically in FIG. 4 and a summary comparison between thesame three configurations is provided in the following table:

Criteria Actual Transversal HP/linear ft 7.3 HP/ft 10.3 HP/ft (3gensets) (4 gensets) Maintenance Good Very good all access sidesUniversal Allows longer Does not allow package engine longer engineModularity Fair Very good friendly Interconnect Fair Very good friendly

Referring to FIGS. 5 and 6, an exploded view of a locomotive 10 withgensets 34 placed in a tranversal configuration is shown to illustratethe positioning of the gensets 34 under the hoods 38. The locomotiveshown in FIGS. 5 and 6 is a GP-9 platform with four gensets 34 and adynamic brake. FIGS. 7-10 show the same locomotive 10 of FIGS. 5 and 6with the gensets 34 and hoods 38 installed.

Referring to FIG. 3, preferably each generator set 100 comprises anengine 102 generally oblong along an engine major axis, a fuel linesupplying fuel to the engine through a fuel filter 104 and an oil linesupplying oil to the engine through an oil filter 106. The generator set100 also comprises an electrical subsystem connected to the engine 102.The electrical subsystem comprises an alternator 108 driven by theengine 102, the alternator 108 being generally oblong along analternator major axis, the alternator major axis being generallyparallel to the engine major axis.

The electrical subsystem also comprises starting batteries 110 forstartup of the engine 102 and positioned on a first side of thealternator 108. The electrical subsystem also comprises a junction box112 for power management of the electrical subsystem and is positionedon the same first side of the alternator 108.

The generator set 100 further comprises an air passage supplying intakeair to the engine 102 through an air filter 114, the air filter 114being generally oblong along an air filter major axis, the air filter114 being positioned above the alternator and the air filter major axisbeing generally perpendicular to the alternator major axis. Thegenerator set 100 also comprises an exhaust pipe 116 for removal ofexhaust gases from the engine 102 through a muffler 118, the muffler 118being generally oblong along a muffler major axis, the muffler 118 beingpositioned above the engine 102, and the muffler major axis beinggenerally parallel to the engine major axis. The generator set 100 alsocomprises a radiator system 120 for cooling of the generator set 100 andconnected to the engine 102, the radiator system 120 being positionedabove the engine. The generator set 100 also comprises an operatingpanel 122 for control of the generator set 100.

Preferably, each generator set (“genset”) has overall dimensions of110″×48″×96″ and comprises a pair of rectangular radiators 124 with twofans or motors 126. The outline of the individual on FIG. 3 illustrateshow there is a good amount of space available for circulation around thegensets on the platform for maintenance, inspection or other purposes.Referring to FIGS. 11 to 14C, the present invention also provides awalkway interface structure 40 for supporting a locomotive sub-assembly44 on a locomotive platform 46 having a platform width. The walkwayinterface structure is part of a modular design consisting of havingstandardized major sub-assemblies that can be easily interfaced from onelocomotive and under frame to another as mentioned previously. As shownin FIG. 11, the walkway interface structure 40 comprises a basestructure 42 supporting the locomotive sub-assembly 44 and having a basewidth substantially corresponding to the platform width. The walkwayinterface structure 40 also comprises at least one interface means 41,as shown in FIG. 17, traversing the base structure 42 for operativelyconnecting the locomotive sub-assembly 44 to another locomotivesub-system 48, like a fuel tank for example.

Preferably, the interface means comprises an element selected from thegroup consisting of traction motor cables, generator set power cables,dynamic brake power cables, power wires, control harnesses, fuel lines,drains, piping lines or ducting.

Preferably, as shown in FIGS. 17 to 19, the walkway interface structure40 may comprise connections 60 for connecting to a further walkwayinterface structure, the further walkway interface structure supportinga further locomotive sub-assembly on the locomotive platform. Henceseveral walkway interface structures may be connected together.Preferably, the connections 60 comprise at least one connection elementalso selected from the group consisting of traction motor cables,generator set power cables, dynamic brake power cables, power cables,power wires, control harnesses, fuel lines, drains, piping lines orducting. The base structure 42 comprises internal passageways 62 forpassage of the connection elements from one end of the walkway interfacestructure to the other, which helps facilitate modular assembly ofseveral walkway interface structures together as pre-run cables andpipes can travel through the base structures along the length of thelocomotive.

FIG. 11 illustrates this modular design concept applied to a roadswitcher locomotive with a GP9 platform. As shown, the walkway interfacestructure 40 (also called Full Walkway Interface) is a structure that isadded over the full width of the platform allowing to pre-run cables andpipes to standard locations. The walkway interface structure 40 isseparated into a number of sections designated as A−B−C−D for the typesof subassemblies it supports. Section A is a standard walkway interfacestructure 40 to be used with operator cab sub-assemblies 50. Section Bis a standard walkway interface structure 40 to be used withsub-assemblies including a high voltage cabinet 52 and a number ofaccessories 54, including batteries, fuel pumps and front traction motorblowers. Section C is a standard walkway interface structure 40 to beused with genset sub-assemblies 56. Section D is a custom walkwayinterface structure 40 to be used with other sub-assemblies 58 includingrear traction motor blowers, air compressors, sand boxes and dynamicbrakes. FIGS. 12A to 12C illustrate how the different sections A−B−C−Dcan be used on different platforms of different lengths. FIG. 12A is aGP9 platform measuring 52′. FIG. 12B is a B23-7 platform measuring58′-4″. FIG. 12C is a SD-40 platform measuring 64′-8″.

The modular design according to the present invention includesstandardized sub-assemblies that can be grouped together in differentconfigurations to fit customer needs:

-   -   Ex1: Block A+B+C+C+C+D for a standard 3 genset configuration on        a GP9 platform    -   Ex2: Block A+B+C+C+E+D for a 2 genset configuration on a longer        platform

Every component needed to interface with the subsystem and the underdeckwould be included in the walkway interface structure.

This mechanical modular design can undergo evolutionary steps. It alsocan be used with gensets positioned in longitudinal configurations andnot only transversal configurations in accordance with the presentinvention. Typically, each walkway interface structure will be 120″ wideby 8″ high by a length “X” to be determined depending on theapplication. The walkway interface structure also has a number ofinterface means, including, but not limited to:

-   -   Traction motor cables (535) for up to 6 axles    -   Genset power cables (4/0) for up to 4 gensets    -   Dynamic brake power cables (4/0)    -   All other small power wires (for air compressors, traction motor        blowers, fans . . . )    -   All control harnesses (lighting, sensors, can wire . . . )    -   Fuel lines from fuel tank and to gensets (suction, returns)    -   Drains from gensets (ecology, lube oil, coolant) and water        collection drain    -   Air brake piping lines    -   Traction Motor Blowers ducting

FIGS. 13 to 14C illustrate Phase 1 of the modular design according tothe present invention applied to road switcher locomotives with gensets56 in a longitudinal configuration and how the different sectionsA−B−C−D−E can be used on different platforms of different lengths. FIGS.13 and 14A is a GP9 platform measuring 52′. FIG. 14B is a B23-7 platformmeasuring 58′-4″. FIG. 14C is a SD-40 platform measuring 64′-8″. FIGS.15 and 16 illustrate another example of the use of a walkway interfacestructure on a GP9 platform.

Although the present invention has been explained hereinabove by way ofpreferred embodiments thereof, it should be understood that theinvention is not limited to these precise embodiments and that variouschanges and modifications may be effected therein without departing fromthe scope or spirit of the invention.

1. A locomotive comprising: a platform deck; and a plurality ofgenerator sets on the platform deck, each generator set occupying aspace associated with a generally oblong footprint on the platform deck,the footprint defining a longitudinal axis along a longest length of thefootprint, wherein each generator set is positioned on the platform decksuch that the longitudinal axis of the corresponding footprint isgenerally perpendicular to a direction of travel of the locomotive. 2.The locomotive according to claim 1, wherein each of the plurality ofgenerator sets comprises: an engine generally oblong along an enginemajor axis; a fuel line supplying fuel to the engine through a fuelfilter; an oil line supplying oil to the engine through an oil filter;an electrical subsystem connected to the engine comprising: analternator driven by the engine, the alternator being generally oblongalong an alternator major axis, the alternator major axis beinggenerally parallel to the engine major axis; and a junction box forpower management of the electrical subsystem and positioned on the firstside of the alternator; an air passage supplying intake air to theengine through an air filter, the air filter being generally oblongalong an air filter major axis, the air filter being positioned abovethe alternator and the air filter major axis being generallyperpendicular to the alternator major axis; an exhaust pipe for removalof exhaust gases from the engine through a muffler, the muffler beinggenerally oblong along a muffler major axis, the muffler beingpositioned above the engine, the muffler major axis being generallyparallel to the engine major axis; a radiator system for cooling of thegenerator set and connected to the engine, the radiator system beingpositioned above the engine; and an operating panel for control of thegenerator set.
 3. A walkway interface structure for supporting alocomotive sub-assembly on a locomotive platform having a platformwidth, the walkway interface structure comprising: a base structureadapted to be removably placed on the locomotive platform, said basestructure supporting the locomotive sub-assembly and having a basestructure width substantially corresponding to the platform width; andat least one interface means traversing the base structure foroperatively connecting the locomotive sub-assembly to another locomotivesub-system.
 4. The walkway interface structure according to claim 3,wherein the at least one interface means comprises an element selectedfrom the group consisting of traction motor cables, generator set powercables, dynamic brake power cables, power cables, power wires, controlharnesses, fuel lines, drains, piping lines or ducting.
 5. The walkwayinterface structure according to claim 3, further comprising connectionsfor connecting to a further walkway interface structure, said furtherwalkway interface structure supporting a further locomotive sub-assemblyon the locomotive platform.
 6. The walkway interface structure accordingto claim 5, wherein the connections comprise at least one connectionelement selected from the group consisting of traction motor cables,generator set power cables, dynamic brake power cables, power cables,power wires, control harnesses, fuel lines, drains, piping lines orducting.
 7. The walkway interface structure according to claim 5,wherein the base structure comprises at least one internal passagewaythrough which the connections extend from a first extremity of thewalkway interface structure to a second opposite extremity of thewalkway interface structure.
 8. The walkway interface structureaccording to claim 4, further comprising connections for connecting to afurther walkway interface structure, said further walkway interfacestructure supporting a further locomotive sub-assembly on the locomotiveplatform.
 9. The walkway interface structure according to claim 8,wherein the connections comprise at least one connection elementselected from the group consisting of traction motor cables, generatorset power cables, dynamic brake power cables, power cables, power wires,control harnesses, fuel lines, drains, piping lines or ducting.
 10. Thewalkway interface structure according to claim 8, wherein the basestructure comprises at least one internal passageway through which theconnections extend from a first extremity of the walkway interfacestructure to a second opposite extremity of the walkway interfacestructure.
 11. The walkway interface structure according to claim 9,wherein the base structure comprises at least one internal passagewaythrough which the connections extend from a first extremity of thewalkway interface structure to a second opposite extremity of thewalkway interface structure.
 12. A locomotive comprising a plurality ofwalkway interface structures as claimed in claim
 3. 13. The locomotiveaccording to claim 1, further comprising a plurality of walkwayinterface structures, each of said plurality of walkway interfacestructures supporting a corresponding one of the plurality of generatorsets on the platform deck and comprising: a base structure adapted to beremovably placed on the locomotive platform deck, said base structuresupporting the corresponding generator set and having a base structurewidth substantially corresponding to the platform width; and at leastone interface means traversing the base structure for operativelyconnecting the corresponding generator set to another locomotivesub-system.
 14. The locomotive according to claim 2, further comprisinga plurality of walkway interface structures, each of said plurality ofwalkway interface structures supporting a corresponding one of theplurality of generator sets on the platform deck and comprising: a basestructure adapted to be removably placed on the locomotive platformdeck, said base structure supporting the corresponding generator set andhaving a base structure width substantially corresponding to theplatform width; and at least one interface means traversing the basestructure for operatively connecting the corresponding generator set toanother locomotive sub-system.
 15. The locomotive according to claim 13,wherein the at least one interface means comprises an element selectedfrom the group consisting of traction motor cables, generator set powercables, dynamic brake power cables, power cables, power wires, controlharnesses, fuel lines, drains, piping lines or ducting.
 16. Thelocomotive according to claim 15, wherein each of the plurality ofwalkway interface structures comprises connections for connecting to anadjacent walkway interface structure.
 17. The locomotive according toclaim 16, wherein the connections comprise at least one connectionelement selected from the group consisting of traction motor cables,generator set power cables, dynamic brake power cables, power cables,power wires, control harnesses, fuel lines, drains, piping lines orducting.
 18. The locomotive according to claim 16, wherein each basestructure of a corresponding walkway interface structure comprises atleast one internal passageway through which the connections extend froma first extremity of the corresponding walkway interface structure to asecond opposite extremity of the corresponding walkway interfacestructure.
 19. The locomotive according to claim 17, wherein each basestructure of a corresponding walkway interface structure comprises atleast one internal passageway through which the connections extend froma first extremity of the corresponding walkway interface structure to asecond opposite extremity of the corresponding walkway interfacestructure.
 20. The locomotive according to claim 14, wherein the atleast one interface means comprises an element selected from the groupconsisting of traction motor cables, generator set power cables, dynamicbrake power cables, power cables, power wires, control harnesses, fuellines, drains, piping lines or ducting, wherein each of the plurality ofwalkway interface structures comprises connections for connecting to anadjacent walkway interface structure, wherein the connections compriseat least one connection element selected from the group consisting oftraction motor cables, generator set power cables, dynamic brake powercables, power cables, power wires, control harnesses, fuel lines,drains, piping lines or ducting, and wherein each base structure of acorresponding walkway interface structure comprises at least oneinternal passageway through which the connections extend from a firstextremity of the corresponding walkway interface structure to a secondopposite extremity of the corresponding walkway interface structure.